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Building
Up an Ignitor Shaft

My son-in-law, a big engine man, has a Webster "MI" low tension
magneto and ignitor that was acting up. The over-the-phone diagnosis was bad
insulating mica washers and a worn ignitor shaft, and the quote for repair was
$125. Wow! The new micas, Fahanstock Clip, contact
and shaft insulator totaled less than $10, delivered. The bulk of the $125 was
the manufacture and installation of the worn shaft.

I tested the bore that the shaft passes through with a 5/16-inch dowel and
found it to be in VERY good shape. The shaft of the ignitor was worn badly
though.

The worn shaft was cleaned with a file and tinned with silver-bearing
solder.

The shaft was then wrapped with tinned copper wire.

The entire assembly was heated with a propane torch and covered with flux
and more solder.

Webster had thoughtfully supplied center holes in the shaft and cast contact
holder. Although the "center" hole in the casting was not centered,
it was usable. The ignitor shaft is shown being turned between centers to a
final diameter of 0.312-inches.

Most of the wire and solder was turned off, leaving a shaft with a
copper/lead surface.

Above is the shaft being installed into the ignitor casting, good as new, I
hope.